Power tool including an air filter and debris collector

This application is a continuation of U.S. patent application Ser. No. 16/552,232 filed on Aug. 27, 2019, now U.S. Pat. No. 11,607,637 which claims priority to U.S. Provisional Patent Application No. 62/744,769 filed on Oct. 12, 2018, and U.S. Provisional Patent Application No. 62/725,899 filed on Aug. 31, 2018, the entire contents of all of which are incorporated herein by reference.

The present invention relates to power tools, and more particularly to power tools including an air filter and debris collector.

During operation of a power tool, debris is generated and operators use filters or vacuums to clean and store the debris.

The present disclosure provides, in one aspect, a power tool including a power tool housing. The power tool housing includes a fluid inlet and a discharge outlet. The power tool also includes a motor, a tool moved relative to the housing by the motor, a fan rotated by the motor such that a fluid flow with debris generated by tool is moved into the fluid inlet by the fan and through the discharge outlet, and a filter that is removably attached to the power tool housing. The filter includes a filter media configured to separate the debris from the flow of fluid, the filter media defining a collection container configured to store the debris. The filter also includes an opening through which the flow of fluid with the debris enters the collection container, and a valve that is moveable between a closed position, in which the opening is closed, and an open position, in which the opening is open. The valve includes a duckbill check valve.

The present disclosure provides, in another aspect, a power tool including a power tool housing. The power tool housing includes a fluid inlet and a discharge outlet. The power tool also includes a motor, a tool moved relative to the housing by the motor, a fan rotated by the motor such that a fluid flow with debris generated by tool is moved into the fluid inlet by the fan and through the discharge outlet, and a filter that is removably attached to the power tool housing. The filter includes a filter media configured to separate the debris from the flow of fluid, the filter media defining a collection container configured to store the debris. The filter also includes an opening through which the flow of fluid with the debris enters the collection container, and a valve that is moveable between a closed position, in which the opening is closed, and an open position, in which the opening is open. The valve includes a zipper.

The present invention provides, in yet another aspect, power tool including a power tool housing, a motor, and a tool coupled to the motor. The tool is movable relative to the power tool housing by the motor. The power tool also includes a filter configured to store debris generated by the tool from a workpiece. The filter including an inlet opening. The power tool also includes an inlet on the power tool housing configured to receive a flow of fluid with the debris, and a fan in fluid communication with the inlet and the inlet opening of the filter. The fan is configured to be rotated by the motor, such that rotation of the fan causes the flow of fluid with the debris to move through the inlet on the power tool housing and into the inlet opening of the filter. The filter is fluidly arranged between the fan and the inlet on the power tool housing, such that the flow of fluid is substantially free of the debris when it passes through the fan.

Other features and aspects of the invention will become apparent by consideration of the following detailed description and accompanying drawings.

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.

illustrate a filter and debris collectorthat can be used with the power tools illustrated in. The filter and debris collectoris not limited to use with only the power tools illustrated in, as will be discussed below. Also, the following disclosure describes several alternative embodiments of the filter, and any of these alternative embodiments could be used in the power tools ofas well as other types of power tools.

The filtercan move between a collapsed position () and an expanded position (). The filtermay be supplied to the consumer in the collapsed position. Then, in one embodiment, the filteris installed in a device in the collapsed position and then automatically moves to the expanded position. The filtercan automatically move to the expanded position by air pressure, gravity, mechanical push or pull, etc. In an alternative embodiment, the consumer moves the filter to the expanded position prior to installing the filter into a device. The filtercan be used to filter any suitable fluid in several applications. For example, the filtercan be used in power tools, vacuum cleaners, air purifiers, HVAC systems, automotive applications, etc.

With reference to, the filterincludes a first or upper housing, a second or lower housing, and filter media. The upper housingincludes an inlet openingthat provides fluid communication into the filter. In some embodiments, a valveis located within the inlet openingto open and close the inlet opening. For example, when the filteris ready to be removed from the device (e.g., power tool), the valveis closed so that debris within the filterdoes not escape through the inlet opening. The upper housinghas an inner volume(see FIG.A) within the housing. Likewise, the lower housingincludes an inner volume. The inner volumes,of the upper housingand the lower housingcan be equal or one of the volumes can be greater than the other. In various alternatives, the inner volumes of one or both of the upper housing and the lower housing are small or inappreciable due to the shape of the housing. The upper housingand the lower housingcan be formed from any suitable material, such as thermoplastic material, thermoset material, molded paper pulp, formed or molded filter media, cardboard, or any other suitable material. Alternatively or additionally, the upper housingforms a support collarfor installing the filterin a device, including a power tool. In other embodiments, the housings,and therefore filtermay have other suitable shapes, for example generally cylindrical.

With reference to, the filter mediaincludes a first endand a second end. The filter mediais coupled to the upper housingproximate the first endwhile, the filter mediais coupled to the lower housingproximate the second end. An inner volumeof the filter mediais defined between the first endand the second endof the filter media. Optionally, the filter mediaincludes one or more pleatsextending between the first endand the second end. The pleatsenable the filterto enlarge beyond the expanded position in a direction transverse to the direction traveled between the collapsed and expanded positions. In other words, the pleatsallow the filterto billow outward in order to collect and store additional debris as the filterfills. The illustrated filter mediatypically includes a seam. Generally, the filter mediais a flat piece that is made tubular by joining two ends together, thereby creating the seam. As shown, the seamis located within one of the pleatsto substantially hide the seam. The seamcan be formed by sewing, heat welding, crimping, or other suitable means of coupling the two ends together. The filter mediacan include any suitable filter media, including a HEPA filter media. In some embodiments, the filter mediacan be reversible and/or washable.

With reference to, the filtercan move between a collapsed position () and an expanded position (). In the collapsed position, the filter mediais located within the inner volumeof the upper housingand/or in the inner volume of the lower housing. Also, the upper housingand the lower housingenclose the filter mediain the collapsed position. In some embodiments, the upper housingand/or lower housingcan snap or otherwise connect together to retain the filterin the collapsed position by interlocking features provided in the upper and lower housings. Alternatively, the filtermay be held in the collapsed position by tape, film, bag, or other attachments. Typically, the filterwould be supplied to the user in the collapsed position. In the expanded position, the filter mediagenerally expands out to an operative length and is ready for use as a filter. In some applications, the filterautomatically moves from the collapsed position to the expanded position. For example, when a flow of dirty fluid enters the filterthrough the inlet opening, the pressure of the fluid automatically expands the filter. In other applications, gravity may automatically expand the filter, or a mechanism may be used to push or pull one or both housings away from the other.

The inner volumeof the filter media, along with the inner volumeof the upper housing, and the inner volumeof the lower housingtogether define a collection containerthat stores debris separated by the filter media. That is, a dirty fluid (e.g., air and dust, dirt, or other particles) travels into the filterthrough the inlet opening. The dirt or dust is separated from the air flow by the filter mediaand relatively clean air flows out of the filterthrough the filter mediabetween the housings,. This airflow is generally represented by the arrows.

The filterfurther includes a first attachment memberthat couples the filter mediato the upper housing. In the illustrated embodiments, the filter media is folded over the first attachment memberbetween the first endand the second endof the filter media, but generally closer to the first end, before it is connected to the upper housing. Stated another way, all or a portion of the first endof the filter mediais folded over before being coupled to the upper housing. Similarly, the filterincludes a second attachment memberthat couples the filter mediato the lower housingbetween the first endand the second endof the filter media, but closer to the second end. The first attachment memberis received within a grooveof the upper housingholding the filter media in place, whereas the second attachment memberis received within a grooveof the lower housing. The grooves,are formed with an inner walland an outer wall. As shown in, the height Hof the outer wallis greater than the height Hof the inner wall. In an alternative embodiment, the height Hof the outer wallis the same as the height Hof the inner wall.

To couple the filter mediato the upper housingin the illustrated embodiment, all or a portion of the end of the filter mediais folded over the first attachment memberand fitted into the grooveof the upper housing. As such, the filter mediais disposed between the grooveand the first attachment member. The fit between the grooveand the attachment memberwith filter mediais a friction or limited clearance fit to wedge the filter mediaand attachment memberinto the grooveto couple the filter mediato the upper housing. Alternatively, the attachment memberis staked, welded, snap fit, adhered, or otherwise fastened to the upper housingto couple the filter mediato the upper housing. In one alternative, at least a portion of the edgeof the first endof the filter mediais retained in the grooveby fitting the attachment memberinto the groove. The connection of the filter mediato the upper housingis provided around the upper housinginhibiting airflow through the connection.

To couple the filter mediato the lower housing, the filter mediais wrapped around the second attachment memberand fitted into the grooveof the lower housingin a similar way as described for the filter mediacoupling to the upper housing. As such, the filter mediais retained in the grooveby fitting the second attachment memberinto the groove. The connection of the filter mediato the lower housingis provided around the lower housinginhibiting airflow through the connection. In various alternatives, the connection of the filter mediato the lower housingmay use a different method than the connection to the upper housing. In one alternative, the filter mediadoes not use a lower housing, instead closing the second endwith a seam or other closure.

The filtermay include a first overlapping filter media sectionand a second overlapping filter media section. The first overlapping filter media sectionis proximate the upper housingand is a result of the first endof the filter mediabeing folded such that at least a portion of the first endextends away from the housingforming the overlapping filter media section. In the illustrated embodiment, the first endof the filter mediais folded over the attachment memberin a manner that the first endextends away from the upper housinga desired length. As such, the filter mediaoverlaps to provide two layers at the first overlapping filter media section. The first overlapping filter media sectionmay extend around the perimeter of the filteror may extend along one or more portions of the perimeter of the filter. In certain embodiments, all or desired portions of the overlapping filter mediamay be trimmed, or filter mediapositioned such that a desired amount of filter mediaextends beyond the attachment memberin predetermined locations. In the embodiment shown in, the first overlapping filter media sectionincludes a notchin a portion. The notchinhibits parts of a power tool (e.g., a conduit that extends into the filter) from catching on the filter media when the conduit inserted and removed from the filter. The second overlapping filter media sectionis proximate the lower housingand is a results of the second attachment memberbending the filter mediain a manner that the second endextends away from the lower housing. As such, the filter mediaoverlaps to provide two layers and forms the second overlapping filter media section. The second overlapping filter media sectionmay extend around the perimeter of the filteror may extend along one or more portions of the perimeter of the filter. In certain embodiments, all or desired portions of the overlapping filter mediamay be trimmed, or filter mediapositioned such that a desired amount of filter mediaextends beyond the second attachment memberin predetermined locations. In the illustrated embodiment, both of the first and second overlapping filter media sections,are disposed in the inner volumeof the filter media. However, for certain embodiments the filtermay be constructed with the overlapping filter media portions,being positioned to the outside of the filter.

As shown in, the upper housingmay include one or more extension membersadjacent the groove. The extensions membersare positioned in a location to direct the overlapping filter media sectionto extend in a direction along the outer wallof the upper housingand filter media. The extension membersmay be integrally formed with the upper housingor may be formed separately and installed in the filter.

As previously mentioned, the first overlapping filter media sectionis proximate the upper housing. The length and width and location of the first overlapping filter media sectionor the second overlapping filter media sectionmay be provided where it is in a direct path of some or all of the airflow (see arrowof) exiting the device (e.g., a discharge conduit of a power tool or vacuum) to receive impact of impinging debris as the debris enters the filter.

One or both of the attachment members,may include a recess, protrusion, or other shapeconfigured for nesting or attaching to a fixture provided to guide the attachment member,into the groove,. As shown in, the attachment member,may include the fixturing recess, protrusion, or other shapeon the side facing out of the groove,.

illustrate a filter. The filtercan move between a collapsed position () and an expanded position (). The filtermay be supplied to the consumer in the collapsed position. Then, in one embodiment, the filteris installed in a device in the collapsed position and then automatically moves to the expanded position. The filtercan automatically move to the expanded position by air pressure, gravity, mechanical push or pull, etc. In an alternative embodiment, the consumer moves the filter to the expanded position prior to installing the filter into a device. The filtercan be used to filter any suitable fluid in several applications. For example, the filtercan be used in power tools, vacuum cleaners, air purifiers, HVAC systems, automotive applications, etc.

Referring to, the filterincludes a first or upper housing, a second or lower housing, and filter media. The upper housingincludes an inlet openingthat provides fluid communication into the filter. In some embodiments, a valve is located within the inlet openingto open and close the inlet opening. For example, when the filteris ready to be removed from the device (e.g., power tool), the valve is closed so that debris within the filterdoes not escape through the inlet opening. The upper housinghas an inner volume(see) within the housing. Likewise, the lower housingincludes an inner volume. The inner volumes of the upper housingand the lower housingcan be equal or one of the volumes can be greater than the other. The upper housingand the lower housingcan be formed from any suitable material, such as thermoplastic material, thermoset material, molded paper pulp, formed or molded filter media, or any other suitable material.

The filter mediaincludes a first end(see). The filter mediais coupled to the upper housingat the first end. Likewise, the filter mediahas a second end and the filter mediais coupled to the lower housingat the second end. As will be discussed in more detail below, the first and second ends of the filter mediacan be attached to the housings,using a variety of methods. An inner volume(see) of the filter mediais defined between the first endand the second end (not shown in) of the filter media.

The inner volumeof the filter media, along with the inner volumeof the upper housing, and the inner volume of the lower housingtogether define a collection containerthat stores debris separated by the filter media. That is, a dirty fluid (e.g., air and dust, dirt, or other particles) travels into the filterthrough the inlet opening. The dirt or dust is separated from the air flow by the filter mediaand relatively clean air flows out of the filterthrough the filter mediabetween the housings,. This airflow is generally represented by the arrowsin.

Referring to, in one embodiment, a panelis located at a seam of the filter media, for example along a vertical seam. In one alternative, the panelis clear to allow a user to see how much debris is in the filterto indicate to the user when the collection containeris full. In addition or in other embodiments, the panelcan be decorative and/or can include odor absorbing material.

Referring to, in an alternative embodiment, the filter may be constructed such that the optional panelmay be provided along a horizontal seam. In this construction, the filter mediais divided into two sections, and the filter mediais attached to the housing. The second piece of filter media′ is attached to the filter media, optionally with the panelprovided along the horizontal seam between the filter media sections,′.

Referring to, the filtercan move between a collapsed position () and an expanded position (). In the collapsed position, the filter mediais located within the inner volume(the inner volume being shown in one embodiment in) of the upper housingand/or in the inner volume of the lower housing. Also, the upper housingand the lower housingenclose the filter mediain the collapsed position. In some embodiments, the upper housingand/or lower housingcan snap or otherwise connect together to retain the filterin the collapsed position by interlocking features provided in the upper and lower housings. Alternatively, the filtermay be held in the collapsed position by tape, film, bag, or other attachments. Typically, the filterwould be supplied to the user in the collapsed position. In the expanded position, the filter mediagenerally expands out to an operative length and is ready for use as a filter. In some applications, the filterautomatically moves from the collapsed position to the expanded position. For example, referring to, when a flow of dirty fluid (represented by arrows) enters the filterthrough the inlet opening, the pressure of the fluid automatically expands the filter. In other applications, gravity may automatically expand the filter, or a mechanism may be used to push or pull one or both housings away from the other.

illustrate a filteraccording to another embodiment. The filterincludes features similar to the filterofand only some differences between the filters,will be discussed. The filterincludes a lower housingthat is generally flat and has very little, if any, inner volume. In the illustrated embodiment, in the collapsed position, the filter mediais virtually entirely received in the inner volume of the upper housing. In this embodiment, the lower housingfunctions as a cap to close the upper housingand retain the filter mediain the collapsed position. Alternatively, at least a portion of the filter mediais received in the inner volume of the upper housing.

illustrate a filteraccording to another embodiment. The filterincludes features similar to the filters discussed above and only some differences between the filters will be discussed. The filterincludes an upper housingthat is generally flat and has very little, if any, inner volume. In the illustrated embodiment, in the collapsed position, the filter mediais virtually entirely received in the inner volume of the lower housing. In this embodiment, the upper housingfunctions as a cap to close the lower housingand retain the filter mediain the collapsed position. Alternatively, at least a portion of the filter mediais received in the inner volume of the lower housing.

illustrate a filteraccording to another embodiment. The filterincludes features similar to the filters discussed above and only some differences between the filters will be discussed. The filterincludes an upper housingand a lower housingand either or both of the upper and lower housings may be generally flat or may have an inner volume. The filterfurther includes an intermediate portion. In the illustrated embodiment, in the collapsed position, the filter mediais received between the housings,and surrounded and enclosed by the intermediate portion. In some embodiments, the intermediate portionis a tear-away style component that remains attached to either the upper housingor the lower housing. For example, there is a perforation or similar attachment between the intermediate portionand the upper housingand/or lower housing. The perforation is torn or broken to allow the filterto move to the expanded position ().illustrates the intermediate portionremaining attached to the upper housingin the expanded position.illustrates the intermediate portionremaining attached to the lower housingin the expanded position. In yet another alternative, the intermediate portion is connected to the upper housing and/or lower housing with engaging features such as snap-fits, friction-fits, protrusions, tabs, hooks, interlocks, or other features that engage corresponding features such as recesses, openings, snap-fits, friction-fits, tabs, protrusions, hooks, interlocks, or other features to connect the intermediate portion with the adjacent housing. Engaging features between the intermediate portion and adjacent housings may be configured so that the connection to one of the adjacent housings is stronger than the connection to the other housing to control whether the intermediate portion remains with the upper housing or the lower housing when moving to the expanded position.

illustrate a filteraccording to another embodiment. The filterincludes features similar to the filters discussed above and only some differences between the filters will be discussed. In the illustrated embodiment, the filterincludes an upper housingand a lower housingand either or both of the upper and lower housings may be generally flat or may have an inner volume. The filterfurther includes an intermediate portion, and in the collapsed position, the filter mediais virtually entirely received between the housings,and surrounded and enclosed by the intermediate portion. In the illustrated embodiment, the intermediate portionis a tear-away style component that the user removes (as illustrated in) from connection with both housings,before using the filter. In some embodiment, the intermediate portioncan be formed by paper, film, tape, paperboard, a sleeve, or other suitable components. In one alternative, the intermediate portion and the lower housing are combined into one removable or tear-away component, with the bottom of the filter media being closed with a seam.

illustrate a filteraccording to another embodiment. The filterincludes features similar to the filters discussed above and only some differences between the filters will be discussed. The filterincludes an upper housingsimilar to the housingof the filterof. The filterfurther includes a lower endof the filter mediathat is closed with a seam, illustrated inas a flat seam or rolled seam. In the collapsed position, the filter mediais entirely received in the inner volume of the upper housing. For example, the filter mediacan be rolled up into the upper housing. In some embodiments, the filter mediais enclosed in the collapsed position in the upper housingby a closure device on the bottom of the upper housing. The closure device can include film, foil, paper, a cap, tape, bag, sleeve, or other suitable devices holding the filter mediaand the upper housingin the collapsed position. The closure device may include a perforation, slit, tear line, or hinge that allows the filter mediato move to the expanded position. In some embodiments, the closure device or cover would remain in place during and after installation of the filterin the device. Then, the device may include a feature that automatically opens or shears the cover allowing the filter media to move to the expanded position. Alternatively or in addition, airflow from the device through the inlet openingcauses the filter mediato automatically expand and tear, push, and/or swing open the closure device, automatically expanding the filter. In other embodiments, the closure device may be removed, such as by peeling or tearing, by the user before or immediately after installing the filter.

illustrate a filteraccording to another embodiment. The filterincludes features similar to the filters discussed above and only some differences between the filters will be discussed. The filterincludes an upper housingsimilar to the housingof the filterofor any other disclosed embodiment. The filterfurther includes a lower end of the filter mediathat includes a gusset bottom. The gusset bottomcan be formed from media material, thermoplastic molded or die cut material, film, foil, or other suitable materials. In some embodiments, the gusset bottomis air permeable. Also in some embodiments, the gusset bottomcan be a self-standing type gusset. In the collapsed position, the filter mediais at least partially received in the inner volume of the upper housing. In some embodiments, the filter mediais enclosed in the collapsed position in the upper housingby a closure device on the bottom of the upper housing. The closure device can include film, foil, paper, a cap, tape, bag, sleeve, or other suitable devices holding the filter mediaand the upper housingin the collapsed position. The closure device may include a perforation, slit, tear line, or hinge that allows the filter mediato move to the expanded position. In some embodiments, the closure device or cover would remain in place during and after installation of the filterin the device. Then, the device may include a feature that automatically opens or shears the cover. Alternatively or in addition, airflow from the device through the inlet openingcauses the filter mediato automatically expand and tear, push, and/or swing open the closure device, automatically expanding the filter. In other embodiments, the closure device may be removed, such as by peeling or tearing, by the user before or immediately after installing the filter.

illustrates one possible way to attach the filter mediato the upper housing(or any of the upper housings described herein). In the embodiment of, the filter mediais welded onto an inside surfaceof a sidewallof the upper housingat the first endof the filter media. The mediacan also be attached to the housingusing adhesive. In other embodiments, including when the upper housingis formed from thermoplastic, the housingmay be overmolded onto the filter media.illustrates the attachment described above with regard toexcept that the housinghas a different shaped sidewalland the endof the filter mediaabuts a top wallof the housing. In the embodiments illustrated in, the attachment is generally radial or transverse to the direction of the filter media, with a mandrel, horn, or other attachment process support being provided through the lower end of the filter prior to the lower end being closed.

illustrates another possible way to attach the filter mediato the upper housing(or any of the upper housings described herein). In the embodiment of, the filter mediais welded onto an inside surfaceof the top wallof the upper housingat the first endof the filter media. Alternatively, the mediacan be attached to the housingusing adhesive. In other embodiments, not shown, when the upper housingis formed from thermoplastic, the housingmay be overmolded onto the filter media.illustrates the attachment described above with regard toexcept that the housinghas a different shaped sidewall. In the embodiments illustrated in, the attachment is generally axial or along the direction of the filter media, with a mandrel, horn, or other attachment process support being provided through the lower end of the filter prior to the lower end being closed.

illustrate how the first endof the filter mediamay be prepared before attaching the filter mediato the housing(similarly, how the second end of the filter mediacould be prepared before attachment to the lower housing).illustrates the first endof the filter mediain its original thickness and the first endcan be attached to the housingin its original thickness. Alternatively, as illustrated in, the filter mediacan be compressed along the first endto create an areaof reduced thickness and increased density. The areaof reduced thickness is where the welding or overmolding to the housingwill be made.illustrates another embodiment where a secondary strip of materialis welded other otherwise attached to the endof the filter media. Then, the secondary strip of materialis welded, overmolded, or otherwise attached to the housing. In some embodiments, the secondary strip of materialincludes a film and/or extrusion and can be applied to one or both sides of the filter media.

illustrate one possible method of attaching the housings,(or other housings discussed herein) onto the filter mediaby overmolding. As shown in, the filter mediais placed into the moldover the mold core being provided through the lower end of the filter prior to the lower end being closed. Then, the material of the housings,is injected over the filter media. In the illustrated method of, the filter mediahaving the reduced thicknessat the endis utilized. The moldshuts off or closes against the mediaat the areaof reduced thickness (near area of arrowin). The injected material adheres to the filter mediaalong the area of reduced thicknessto attach the filter mediato the housings,. In various alternatives, filter media having end treatment shown inmay be utilized.

In another alternative, as discussed with reference to, the filter mediamay be divided into at least two portions, with the first portion of the filter mediabeing attached to the upper housing. Attaching a smaller portion of media to the upper may be useful in handing the filter media in a welding or molding process where internal support is needed. Then, after attachment of the first portion to the upper housing, the second piece of filter media′ is attached to the first portion of filter mediausing traditional bonding, sewing, or welding techniques. In one embodiment, not shown, the panelis attached directly to the upper housing by welding, overmolding, adhesive, or other technique, and the filter mediais attached to the panel.

illustrates a possible way to attach the filter mediato the lower housing(or any of the lower housings described herein). In the embodiment of, the filter mediais welded onto an outside surfaceof a sidewallof the lower housingat the second endof the filter media. The filter mediacan also be attached to the housingusing adhesive.illustrates one possible way to attach the filter mediato a flat lower housing(similarly could be used to attach to a flat upper housingor any of the housings described above). A ringoptionally having projectionsmay be fitted to capture the lower end of the filter mediabetween the ring and the housingand may be heat staked or otherwise fastened to attach the filter mediaand the housing.

illustrates an alternative embodiment where a portionof the upper housingis formed by the filter media, generally by making the filter mediain the portionmore rigid or stiffer than the other areas of the filter media. The portionis stiffened by compression molding, vacuum thermoforming, or a combination of both, and/or coating/impregnating the portionwith thermoset, thermoplastic, or other material to make a rigid or semi rigid upper portion having a desired shape made with the filter media. An inlet piece, including the inlet opening, is inserted through an apertureof the portion. The inlet piececan be attached by welding or adhesive. In the illustrated embodiment, the inlet pieceis attached to the inside of the portionand in other embodiments, the inlet piecemay be attached to the outside of the portion. In another embodiment, the inlet piece is overmolded onto the filter media before, during, or after the stiffening operation.

illustrates an alternative embodiment where the filter mediais formed with a generally closed end except for aperture. Then, the filter mediais attached to the housingwith the aperturealigned with the inlet opening. The attachment could be made by welding or adhesive around the aperture.

illustrate an alternative embodiment where the housingor housingare formed by folding a die cut shape(). The shapeis die cut and then folded to create the housingor. The filter media can be attached to the housingsorby welding or adhesive. In other embodiments, the housing can be formed from a single piece hinged from a top piece. The top and bottom die cut pieces could be separated and then bonded to each other or separately to the filter media by the methods previously discussed.

illustrate a filteraccording to another embodiment. The filterincludes features similar to the filters discussed above and only some differences between the filters will be discussed. The filterincludes an upper housingthat includes a bag. In one embodiment, filter mediais formed as a complete enclosure with a desired inlet. The filter media is compacted and inserted into an open end of the bagand then the bag sealed, or alternatively, the bagformed and sealed around the compacted media. Optionally, the bagis attached to the filter material around the inlet. The bagcan be formed from foil, plastic, paper, or other suitable materials. The bagincludes a tear-out bottomopposite the inletat the top of the bag. In some applications, the bagis installed into the device with the filter mediain the collapsed position (). Then, when the device is used or turned on, the filter mediaautomatically breaks through the bottomof the bagbecause of the airflow through the inlet. Alternatively, the bag includes a portion that the user opens before loading into a device, such as a tear-away portion, tear or cut line, or other opening. In yet another alternative, a mechanism may be used to push or pull one end of the filter away from the other moving the filter to the expanded position.

illustrates a power tool. The power toolin the illustrated embodiment is a sander. The sanderincludes a housing, a motorinside the housing, and a tool. In the illustrated embodiment, the toolincludes a padand a sheet of sand paperremovably coupled to the pad. The sanderfurther includes a batterythat provides power to the motor. The sanderfurther includes a dust collector housingand a ductthat provides fluid communication into the dust collector housing. In one embodiment, the sanderincludes a faninside the housingand adjacent the pad. The fanis in fluid communication with the ductand the fan blows dust and debris into the dust collector housingthrough the duct. Any one of the filters,,,,,,,,, discussed above, can be located inside the dust collector housingand in fluid communication with the duct. Although the illustrated sanderis a random orbit sander, the filters,,,,,,,,, discussed above, can be used with other types of sanders, including belt sanders, orbital sanders, spindle sanders, drum sanders, and the like.

In operation, the motorrotates the padand the sand paperto sand a workpiece (e.g., wood), which creates dust. The dust is blown by the fan through the ductand into the filter (e.g., filter) inside the dust collector housing. The filterseparates the dust from the air flow and the dust is retained in the filterwhile the relatively clean air is exhausted from the filterand the dust collector housing. When the filteris full, the user removes and replaces the filterwith a new filter. As discussed above, in one embodiment, the filterincludes a valvethat is automatically closed when the filteris removed from the ductto inhibit the dust from escaping the filterafter the filteris removed.

illustrates another example of a power toolthat can utilize any one of the filters,,,,,,,,, discussed above. In the illustrated embodiment, the power toolis a circular saw that includes a saw blade. The sawfurther include a guardthat partially surrounds the blade. The guarddefines a duct that includes a discharge. The filter (e.g., filter) can be coupled to the dischargeso that the filterreceives debris, dust, and air flow from the discharge. In operation, rotation of the saw bladegenerates an air flow in the guardthat propels dust and debris through the dischargeand into the filter. When the filteris full, the user removes and replaces the filterwith a new filter. The filterseparates the dust and debris (e.g., saw dust, wood chips, etc.) from the air flow and the debris and dust is retained in the filterwhile the relatively clean air is exhausted from the filter. As discussed above, in one embodiment, the filterincludes a valvethat is automatically closed when the filteris removed from the dischargeto inhibit the dust from escaping the filterafter the filteris removed.

Although the sawis a circular saw, the filters,,,,,,,,, discussed above, can be used with other types of saws. For example,illustrates a miter sawthat includes a filter (e.g., filter) that separates and stores debris and dust generated by the saw. In yet other embodiments, other suitable types of saws can include the filters,,,,,,,,, discussed above, including table saws, reciprocating saws, band saws, jig saws, reciprocating saws and the like.

illustrates another type of power toolthat can include one of the filters,,,,,,,,, discussed above. In the illustrated embodiment, the power toolis a dust extractor that is attached to a drill, including a hammer drill. Although the illustrated dust extractoris a universal dust extractor that can be attached to other drills, in other embodiments, the dust extractor can be an extractor that is dedicated for use with a single drill. The dust extractorincludes a nozzleand a suction source (e.g., motor and fan)in fluid communication with the nozzle. In operation, the dust extractoris attached to a drill. The drill includes a drill bit that creates dust or debris. The dust/debris is drawn through the nozzleby the suction sourceand into the filter. The filterseparates the dust from the air flow and the dust is retained in the filterwhile the relatively clean air is exhausted from the filterand travels through the suction sourcebefore being exhausted. When the filteris full, the user removes and replaces the filterwith a new filter. As discussed above, in one embodiment, the filterincludes a valvethat is automatically closed when the filteris removed to inhibit the dust from escaping the filterafter the filteris removed. Although the illustrated dust extractoris configured for use with a drill, in other embodiments, the dust extractor can be configured for use with other types of power tools, including a grinder.

illustrates another type of power toolthat can include one of the filters,,,,,,,,. The illustrated power toolis a vacuum cleaner, particularly a battery powered backpack vacuum cleaner. In other embodiments, the vacuum cleanercan be another type of vacuum cleaners, including a wet/dry vacuum cleaner.